No. 6489 Ford Cam and Valve Train Tool Kit

Transcription

Parts List & Operating Instructions
Parts List & Operating Instructions for
Form No. 107267
No. 6489
Ford
Cam and Valve Train Tool Kit
511532 (6009)
511555 (6020)
511533 (6466)
511534 (6467)
511535 (6468)
511536 (6469)
511537 (6470)
511538 (6471)
511539 (6472)
511540 (6473)
511541 (6474)
511542 (6475)
511543 & 511544 (6476)
511545 (6477)
511546 (6478)
511547 (6479)
511548 (6480)
511549 (6481)
511550 (6482)
511551 (6483)
511552 (6484)
511553 & 511554 (6485)
1
2
Form No. 107267
Ford Tool Application Chart
Year
Model
Engine
Tool Description
Part No.
Ford
American
Part No.
Ford
Global Part
No.
1995-1997
Aerostar
3.0L V6
Cam Sensor Synch Tool
6472 (511539)
T95T-12200-A
303-529
1996-1998
Aerostar
4.0L V6
6472 (511539)
T95T-12200-A
303-529
1994-2002
Contour
2.0L 4 cyl. VIN 3
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
1997-2002
Contour
2.0L 4 cyl. VIN 3
Crankshaft TDC Timing Pin
6475 (511542)
T97P-6000-A
303-574
1999-2002
Cougar
2.0L VIN 3
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
1997
Cougar
3.8L V6
6469 (511536)
T96T-12200-A
303-562
1991-2008
Crown Victoria
4.6L 2V V8
Cam Positioning Tool
6009 (511532)
T91P-6256-A
303-380
1992-2008
Crown Victoria
4.6L 2V V8
6020 (511555)
T92P-6256-A
303-413
1997-2002
Crown Victoria
4.6L VIN W
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
1997-2008
Econoline
4.2L V6
6469 (511536)
T96T-12200-A
303-562
1997-2009
Econoline
4.6L VIN W
Cam Holding Tool
6477 (511545)
T96T-6256-B
303-557
1997-2014
Econoline
4.6L VIN W
6020 (511555)
T92P-6256-A
303-413
1997-1998
Econoline
4.6L & 5.4L V8, 6.8L V10
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
1997-2002
Econoline
4.6L & 5.4L
6476 (511543 & 4)
T96T-6256-AR
303-S568
1997-2002
Econoline
5.4L V8
Cam Holding Tool
6477 (511545)
T96T-6256-B
303-557
1997-2002
Econoline
6.8L V10
Cam Holding Tool
6476 (511543 & 4)
6477 (511545)
T96T-6256-AR
T96T-6256-B
303-S568
303-557
2012-2014
Edge
2.0L VIN 9
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
2001-2004
Escape
2.0L VIN B
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
2013-2014
Escape
2.0L VIN 9
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
2005-2008
Escape
2.3L VIN Z
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2009-2014
Escape
2.5L VIN 7
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2005-2008
Escape Hybrid
2.3L VIN H
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2009-2012
Escape Hybrid
2.5L VIN 3
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
1997-2002
Expedition
4.6L VIN W
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
1997-2002
Expedition
5.4L
Cam Holding Tool
6009 (511532)
6020 (511555)
6476 (511543 & 4)
6477 (511545)
T91P-6256-A
T92P-6256-A
T96T-6256-AR
T96T-6256-B
303-380
303-413
303-S568
303-557
2012-2014
Explorer
2.0L VIN 9
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
1996-1998
Explorer
4.0L V6
6472 (511539)
T95T-12200-A
303-529
1997-2008
Explorer
4.0L SOHC VIN X
Cam Gear Holding Tool
Crankshaft Holding Tool
Cam Holding Tool Adapter
Cam Holding Tool
Cam Gear Holding Tool Adapter
Timing Chain Tensioner Tool
Cam Gear Bolt Socket & Extension
6478 (511546)
6479 (511547)
6480 (511548)
6481 (511549)
6482 (511550)
6484 (511552)
6485 (511553 & 4)
T97T-6256-B
T97T-6303-A
T97T-6256-D
T97T-6256-C
T97T-6256-A
T97T-6K254-A
T97T-6256-F, -G
303-564
303-573
303-576
303-577
303-578
303-571
303-565, -575
3
Year
Model
Engine
Tool Description
Part No.
Ford
American
Part No.
1997-2011
Explorer
4.0L SOHC V6 VIN E
Cam Holding Tool
6478 (511546)
6479 (511547)
6480 (511548)
6481 (511549)
6482 (511550)
6484 (511552)
6485 (511553 & 4)
1999-2002
Explorer
4.0L Push Rod V6
6483 (511551)
1997-2002
Explorer
4.6L VIN W
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
1996-1998
Explorer
5.0L V8
6469 (511536)
T96T-12200-A
303-562
1999-2002
Explorer
5.0L V8
6470 (511537)
1997-2004
F-150
4.6L VIN 6
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
1997-2010
F-150
4.6L VIN W
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
1997-2008
F-Series Truck
4.2L
6469 (511536)
T96T-12200-A
303-562
1997-1998
F-Series Truck
4.6L
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
1997-2002
F-Series Truck
4.6L
6476 (511543 & 4)
T96T-6256-AR
303-S568
1997-2009
F-Series Truck
4.6L VIN W
Cam Holding Tool
6477 (511545)
T96T-6256-B
303-557
1997-2002
F-Series Truck
5.4L
6009 (511532)
6476 (511543 & 4)
6020 (511555)
T91P-6256-A
T96T-6256-AR
T92P-6256-A
303-380
303-S568
303-413
1997-2002
F-Series Truck
5.4L
Cam Holding Tool
6477 (511545)
T96T-6356-B
303-557
2012-2014
Focus
2.0L VIN 2
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
2000-2004
Focus
2.0L VIN 3
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
2002-2004
Focus
2.0L VIN 5
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
2005-2011
Focus
2.0L VIN N
6475 (511542)
T97P-6000-A
303-574
2005-2012
Focus
2.0L VIN N
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2003-2007
Focus
2.3L VIN Z
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2004-2007
Freestar
3.9L VIN 6
6470 (511537)
2004-2007
Freestar
4.2L
6469 (511536)
T96T-12200-A
303-562
2013-2014
Fusion
2.0L
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
2006-2009
Fusion
2.3L VIN Z
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2010-2014
Fusion
2.5L VIN A
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2010-2014
Fusion Hybrid
2.5L VIN 3
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
1991-2008
Grand Marquis
4.6L 2V
6009 (511532)
T91P-6256-A
303-380
1992-2008
Grand Marquis
4.6L 2V
6020 (511555)
T92P-6256-A
303-413
1997-2002
Grand Marquis
4.6L VIN W
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
2005-2008
Mariner
2.3L VIN Z
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2009-2012
Mariner
2.5L VIN 7
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2005-2008
Mariner Hybrid
2.3L VIN H
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2009-2012
Mariner Hybrid
2.5L VIN 3
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2006-2009
Milan
2.3L VIN Z
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2010-2011
Milan
2.5L
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
4
T97T-6256-B
T97T-6303-A
T97T-6256-D
T97T-6256-C
T97T-6256-A
T97T-6K254-A
T97T-6256-F, -G
Ford
Global Part
No.
303-564
303-573
303-576
303-577
303-578
303-571
303-565, -575
303-638
303-630
303-630
Form No. 107267
Year
Model
Engine
Tool Description
Part No.
Ford
American
Part No.
Ford
Global Part
No.
2010-2012
Milan Hybrid
2.5L VIN 3
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2014
MKT
2.0L
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
2012
MKX
2.0L VIN 9
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2013-2014
MKZ
2.0L
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
2006-2009
MKZ
2.3L VIN Z
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2010-2012
MKZ
2.5L VIN A
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2010-2012
MKZ Hybrid
2.5L VIN 3
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
2004
Monterey
3.9L VIN 6
6470 (511537)
2004-2007
Monterey
4.2L
6469 (511536)
T96T-12200-A
303-562
1997-2008
Mountaineer
4.0L SOHC VIN X
Cam Holding Tool
6478 (511546)
6479 (511547)
6480 (511548)
6481 (511549)
6482 (511550)
6484 (511552)
6485 (511553 & 4)
T97T-6256-B
T97T-6303-A
T97T-6256-D
T97T-6256-C
T97T-6256-A
T97T-6K254-A
T97T-6256-F, -G
303-564
303-573
303-576
303-577
303-578
303-571
303-565, -575
1997-2011
Mountaineer
4.0L SOHC V6 VIN E
Cam Holding Tool
6478 (511546)
6479 (511547)
6480 (511548)
6481 (511549)
6482 (511550)
6484 (511552)
6485 (511553 & 4)
T97T-6256-B
T97T-6303-A
T97T-6256-D
T97T-6256-C
T97T-6256-A
T97T-6K254-A
T97T-6256-F, -G
303-564
303-573
303-576
303-577
303-578
303-571
303-565, -575
1999-2002
Mountaineer
4.0L Push Rod V6
6483 (511551)
1997-2005
Mountaineer
4.6L VIN W
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
1996-1998
Mountaineer
5.0L V8
6469 (511536)
T96T-1220-A
303-562
1999-2002
Mountaineer
5.0L V8
6470 (511537)
1996-1998
Mustang
3.8L V6
6469 (511536)
1999-2004
Mustang
3.8L V6
6470 (511537)
2005-2010
Mustang
4.0L SOHC VIN N
Cam Holding Tool
6478 (511546)
6479 (511547)
6480 (511548)
6481 (511549)
6482 (511550)
6484 (511552)
6485 (511553 & 4)
T97T-6256-B
T97T-6303-A
T97T-6256-D
T97T-6256-C
T97T-6256-A
T97T-6K254-A
T97T-6256-F, -G
303-564
303-573
303-576
303-577
303-578
303-571
303-565, -575
1997-2002
Mustang
4.6L VIN W
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
1996-2004
Mustang
4.6L VIN X
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
2003-2004
Mustang
4.6L VIN Y
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
1994-2002
Mystique
2.0L 4 cyl. VIN 3
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
1997-2002
Mystique
2.0L 4 cyl. VIN 3
Crankshaft TDC Timing Tool
6475 (511542)
T97P-6000-A
303-574
1998-1999
Navigator
5.4L
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
1998-2002
Navigator
5.4L
Cam Holding Tool
6476 (511543 & 4)
6477 (511545)
T96T-6256-AR
T96T-6256-B
303-S568
303-557
2001-2011
Ranger
2.3L VIN D
Cam Alignment Tool
6474 (511541)
T94P-6256-CH
303-465
1995-1997
Ranger
3.0L V6
6472 (511539)
T95T-12200-A
303-529
303-630
303-638
303-630
T96T-12200-A
303-562
303-630
5
Year
Model
Engine
Tool Description
Part No.
Ford
American
Part No.
Ford
Global Part
No.
1998-2008
Ranger
3.0L V6
6473 (511540)
1996-1998
Ranger
4.0L V6
6472 (511539)
T95T-12200-A
303-529
1997-2011
Ranger
4.0L SOHC VIN E
Cam Holding Tool
6478 (511546)
6479 (511547)
6480 (511548)
6481 (511549)
6482 (511550)
6484 (511552)
6485 (511553 & 4)
T97T-6256-B
T97T-6303-A
T97T-6256-D
T97T-6256-C
T97T-6256-A
T97T-6K254-A
T97T-6256-F, -G
303-564
303-573
303-576
303-577
303-578
303-571
303-565, -575
1997-2008
Ranger
4.0L SOHC VIN X
Cam Holding Tool
6478 (511546)
6479 (511547)
6480 (511548)
6481 (511549)
6482 (511550)
6484 (511552)
6485 (511553 & 4)
T97T-6256-B
T97T-6303-A
T97T-6256-D
T97T-6256-C
T97T-6256-A
T97T-6K254-A
T97T-6256-F, -G
303-564
303-573
303-576
303-577
303-578
303-571
303-565, -575
2003-2011
Ranger
4.0L SOHC
6485 (511553 & 4)
T97T-6256-F, -G
303-565, -575
1999-2000
Ranger
4.0L Push Rod
6483 (511551)
1996-1997
Sable
3.0L V6 2V
6472 (511539)
1998-2005
Sable
3.0L V6 VIN U
6473 (511540)
1998-2006
Sable
3.0L V6 VIN Z
6473 (511540)
2013-2014
Taurus
2.0L
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
1996-1997
Taurus
3.0L V6 2V
6472 (511539)
T95T-12200-A
303-529
1998-2005
Taurus
3.0L V6 VIN U
6473 (511540)
1998-2006
Taurus
3.0L V6 VIN Z
6473 (511540)
1997
Thunderbird
3.8L V6
6469 (511536)
T96T-12200-A
303-562
1997-2002
Town Car
4.6L VIN W
6009 (511532)
6020 (511555)
T91P-6256-A
T92P-6256-A
303-380
303-413
2010-2013
Transit
2.0L VIN N
Cam Alignment Tool
6474 (511541)
6475 (511542)
T94P-6256-CH
T97P-6000-A
303-465
303-574
1995-1997
Windstar
3.0L V6
6472 (511539)
T95T-12200-A
303-529
1998-2003
Windstar
3.0L V6 VIN U
6473 (511540)
1996-1998
Windstar
3.8L V6
6469 (511536)
1999-2003
Windstar
3.8L V6
6470 (511537)
2006-2009
Zephyr
2.3L VIN Z
Cam Alignment Tool
6474 (511541)
Get parts at OTCparts.com
6
303-589
303-638
T95T-12200-A
303-529
303-589
303-589
303-589
303-589
303-589
T96T-12200-A
303-562
303-630
T94P-6256-CH
303-465
Form No. 107267
511532 (6009) Ford Camshaft Positioning Tool
Application: 1991 – 2008 4.6L 2V Crown Victoria (V8), Grand Marquis
1997 – 1998 4.6L & 5.4L V8, 6.8L V10 Econoline
1997 – 2002 5.4L Expedition
1997 – 2002 4.6L Expedition, Explorer, Crown Victoria,
Grand Marquis, Town Car (VIN W)
1997 – 2004 4.6L F-150 (VIN 6)
1997 – 2010 4.6L F-150 (VIN W)
1997 – 1998 4.6L
F-Series Truck
same as 1997 – 2002 5.4L F-Series Truck
Ford No. 303-380
1997 – 2005 4.6L Mountaineer (VIN W)
(T91P-6256-A)
1997 – 2002 4.6L Mustang (VIN W)
1996 – 2004 4.6L Mustang (VIN X)
2003 – 2004 4.6L Mustang (VIN Y)
1998 – 1999 5.4L Navigator
Note: The 1991 4.6L 2V V8 application does not require the use of tool No. 511555 (6020).
CAUTION: To prevent damage to valves and pistons, do NOT rotate the crankshaft and/or camshaft(s)
when removing timing chain(s) and installing cylinder heads. Because this is not a free-wheeling
engine, if it has "jumped time," there will be damage to the valves and/or pistons, which will require
the removal of the cylinder heads. The cam sprocket should be disassembled from the camshaft only
when one of the components must be replaced.
1. Remove all necessary components to access the timing chains.
2. Rotate the engine to No. 1 TDC.
3. Assemble tools :
• 1991 4.6L 2V V8 : Refer to Figure 1. Install No. 511532 (6009) on flats of the camshaft to prevent accidental
rotation of the camshafts.
• All other applications : Refer to Figure 2. Install No. 511532 (6009) and Cam Positioning Tool No. 511555
(6020) into each camshaft end before removing (or installing) timing chain tensioners and chains—this
prevents valve train damage.
4. Perform camshaft service as required.
5. Refer to the vehicle service manual for the correct camshaft-to-crankshaft timing procedure.
WARNING: Wear eye
protection that meets ANSI
Z87.1 and OSHA standards.
No. 511532 (6009)
Ford Camshaft Positioning Tool
No. 511555 (6020)
Ford Camshaft
Positioning Tool
Figure 1
The 1991 4.6L 2V V8 application does not require
the use of tool No. 6020.
Figure 2
All other applications.
7
511555 (6020) Ford Camshaft Positioning Tool
Application: 1992 – 2008 4.6L 2V Crown Victoria (V8), Grand Marquis
1997 – 2002 4.6L Crown Victoria, Expedition, Explorer
Grand Marquis, Town Car (VIN W)
1997 – 1998 4.6L & 5.4L V8, 6.8L V10 Econoline
1997 – 2012 4.6L Econoline (VIN W)
1997 – 2002 5.4L Expedition
1997 – 2004 4.6L F-150 (VIN 6)
1997 – 2010 4.6L F-150 (VIN W)
1997 – 1998 4.6L
F-Series Truck
1997 – 2002 5.4L
F-Series Truck
1997 – 2005 4.6L Mountaineer (VIN W)
1997 – 2002 4.6L Mustang (VIN W)
1996 – 2004 4.6L Mustang (VIN X)
2003 – 2004 4.6L Mustang (VIN Y)
1998 – 1999 5.4L
Navigator
Note: Tool No. 511555 (6020; same as Ford No. 303-413/T92P-6256-A) must be used with tool
No. 511532 (6009; same as Ford No. 303-380/T91P-6256-A).
CAUTION: To prevent damage to valves and pistons, DO NOT rotate the crankshaft and/or camshaft(s)
when removing the timing chain(s) and installing the cylinder heads. Because this is not a free-wheeling
engine, if it has "jumped time" there will be damage to the valves and/or pistons, which will require the removal
of the cylinder heads. The cam sprocket should be disassembled from the camshaft only when one of the
components must be replaced.
1. Remove all necessary components to access the timing chains.
2. Rotate the engine to No. 1 top dead center.
3. Disassembly: Install Camshaft Positioning
Tool (511555/6020) and Cam Positioning Tool
(511532/6009) into each camshaft end, as
shown, before removing timing chain tensioners
and chains to prevent valve train damage.
No. 511532 (6009)
Ford Camshaft
Positioning Tool
4. Assembly: Install Camshaft Positioning Tool
No. 511555 (6020)
(511555/6020) and Cam Positioning Tool
Ford Camshaft
(511532/6009) into each camshaft end, as shown, Positioning Tool
before installing timing chains and tensioners to
prevent valve train damage.
WARNING: Wear eye
8
Form No. 107267
511533 (6466) Ford Crankshaft Sensor Positioner
Application: 1989 – 1997 Ford Ranger w/ 2.3L, 4 cyl., dual plug engine
Note: Same as Ford No. 303-354 (T89P-6316-A).
1. Install Crankshaft Sensor Positioner
No. 6466 (511533) on sensor as shown.
No. 6466
(511533)
2.Rotate crankshaft so outer vane
on crankshaft pulley hub assembly
engages both sides of tool. Tighten
sensor assembly retaining bolts to
specifications.
3. Rotate crankshaft so vane on crankshaft
pulley hub assembly is no longer
engaged in tool. Remove tool.
Outer vane of
crankshaft pulley
hub assembly.
WARNING: Wear eye
511534 (6467) Ford Camshaft Sensor Synchronizer Tool
Application: 1990 – 1997 3.8L V6 Thunderbird/Cougar
1989 – 1995 3.8L V6 Supercharged Thunderbird/Cougar
1994 – 1998 3.8L V6 Mustang
1998 3.8L V6 Windstar
CAUTION: Before removing the camshaft sensor housing
assembly, note the position of the camshaft sensor electrical
connector. The connector MUST be reassembled in the same
position during installation.
1.Rotate crankshaft to set No. 1 cylinder at 26° after top dead
center of the compression stroke.
2.Engage camshaft sensor housing vane in slot of tool No. 6467
(511534).
Camshaft
Sensor
Housing
3.Rotate tool on camshaft sensor housing until tool engages housing
notch. (Tool should be square and in contact with entire top of
housing.)
4.Install camshaft sensor housing and tool assembly into engine
according to instructions in the vehicle service manual. Torque
fasteners to factory specifications.
WARNING: Wear eye
9
511535 (6468) Ford Camshaft Pulley Holding Tool
Application: 1993 – 1997 Ford Probe w/ 2.0L, 4 cyl., engine
Note: Same as Ford No. 303-398 (T92C-6256-AH).
1. Rotate engine to align camshaft
timing marks with crankshaft
timing marks.
2.Insert No. 6468 (511535)
between intake and exhaust cam
pulleys. The tool will fit correctly
only one way. The side of tool
marked UP must be facing the
technician and top of engine.
3. Follow vehicle service manual
procedure to service timing belt
as required. Remove tool when
finished.
No. 6468 (511535)
WARNING: Wear eye
Application:
1997
1997 – 2008
1996 – 1998
2004 – 2007
1996 – 1998
3.8L V6 Cougar, Thunderbird
4.2L V6 Econoline, F-Series Truck
5.0L V8 Ford Explorer, Mercury Mountaineer
4.2L
Freestar, Monterey
3.8L V6 Mustang, Windstar
Note: Same as Ford No. 303-562 (T96T-12200-A).
assembly, note the position of the camshaft sensor
electrical connector. To prevent equipment damage, the
connector MUST be reassembled in the same position
during installation.
No. 511536
(6469)
Camshaft
Sensor
Housing
1.Rotate crankshaft to set No. 1 cylinder at top dead center of
the compression stroke.
2.Engage camshaft sensor housing vane in slot of tool No.
511536 (6469).
3.Rotate tool on camshaft sensor housing until tool engages
housing notch. (Tool should be square and in contact with
entire top of housing.)
10
WARNING: Wear eye
Form No. 107267
Application: 1999 – 2002 5.0L V8 Explorer, Mountaineer
2004 – 2007 3.9L
Freestar (VIN 6)
20043.9L
Monterey (VIN 6)
1999 – 2004 3.8L V6 Mustang
1999 – 2003 3.8L V6 Windstar
No. 511537
(6470)
Note: Same as Ford No. 303-630.
connector. To prevent equipment damage, the connector
MUST be reassembled in the same position during installation.
Camshaft
Sensor
Housing
compression stroke.
(6470).
housing notch. (Tool should be square and in contact with entire
top of housing.)
WARNING: Wear eye
Application: 1993 – 1995 3.0L V6 Ford Taurus/Mercury Sable
No. 6471
(511538)
connector. The connector MUST be reassembled in the same
position during installation.
compression stroke.
(511538).
housing.)
Camshaft
Sensor
Housing
WARNING: Wear eye
11
511539 (6472) Ford Camshaft Positioning Tool Set
Application: 1995 – 1997 3.0L V6 Aerostar, Ranger, Windstar
1996 – 1998 4.0L V6 Aerostar, Explorer, Ranger
1996 – 1997 3.0L V6 2V Sable, Taurus
No. 511539
(6472)
511539
1. Rotate crankshaft to set No. 1 cylinder at TDC of
compression stroke.
2. Engage camshaft sensor housing vane in slot of tool No.
511539 (6472).
3. Rotate tool on camshaft sensor housing until tool engages
4. Install camshaft sensor housing and tool assembly into
engine according to instructions in the vehicle service
manual. Torque fasteners to factory specifications.
WARNING: Wear eye
Application: 1998 – 2008
1998 – 2005
1998 – 2006
1998 – 2003
3.0L V6 Ranger
3.0L V6 Sable, Taurus (VIN U)
3.0L V6 Sable, Taurus (VIN Z)
3.0L V6 Windstar
1.Rotate crankshaft to set No. 1 cylinder at top dead center
of compression stroke.
No. 511540
(6473)
Camshaft
Sensor
Housing
2.Engage camshaft sensor housing vane in slot of tool No.
511540 (6473).
4.Install camshaft sensor housing and tool assembly into
engine according to instructions in the vehicle service
manual. Torque fasteners to factory specifications.
12
WARNING: Wear eye
Form No. 107267
511541 (6474) Ford Camshaft Alignment Tool
1999 – 2002
2012 – 2014
2001 – 2004
2013 – 2014
2005 – 2008
2009 – 2014
2005 – 2008
2009 – 2012
2012 – 2014
2000 – 2004
2002 – 2004
2005 – 2012
2003 – 2007
2006 – 2009
2010 – 2014
2010 – 2014
2009 – 2012
2010 – 2011
2010 – 2012
2014
2012
2010 – 2012
2001 – 2011
2010 – 2013
2.0L 4 cyl. Contour, Mystique (VIN 3)
2.0L Cougar (VIN 3)
2.0L Edge, Explorer (VIN 9)
2.0L Escape (VIN B)
2.0L Escape (VIN 9), Fusion, MKZ, Taurus
2.3L Escape, Mariner (VIN Z)
2.5L Escape (VIN 7)
2.3L Escape Hybrid, Mariner Hybrid (VIN H)
2.5L Escape Hybrid, Mariner Hybrid (VIN 3)
2.0L Focus (VIN 2)
2.0L Focus (VIN 3)
2.0L Focus (VIN 5)
2.0L Focus (VIN N)
2.3L Focus (VIN Z)
2.3L Fusion, Milan, MKZ, Zephyr (VIN Z)
2.5L Fusion (VIN A)
2.5L Fusion Hybrid (VIN 3)
2.5L Mariner (VIN 7)
2.5L Milan
2.5L Milan Hybrid, MKZ Hybrid (VIN 3)
2.0L MKT
2.0L MKX (VIN 9)
2.5L MKZ (VIN A)
2.3L Ranger (VIN D)
2.0L Transit (VIN N)
CAUTION: The Camshaft Alignment Tool is for
camshaft alignment only. Using this tool to
prevent rotation can result in engine damage.
Note:
• Same as Ford No. 303-465 (T94P-6256-CH).
• The camshaft timing slots are offset. If the
camshaft alignment timing tool cannot be installed,
rotate the crankshaft one complete revolution
clockwise to correctly position the camshafts.
1. Rotate engine to top dead center on the No. 1 cylinder.
2. Align camshafts by installing tool No. 511541 (6474) into the slots at the rear of the camshafts as shown.
3. Service the timing belt as required according to instructions in the vehicle service manual.
4. Torque fasteners to factory specifications.
5. Remove the tool.
WARNING: Wear eye
No. 511541
(6474)
13
511542 (6475) Ford Crankshaft TDC Timing Pin
Application: 1997 – 2002 2.0L 4 cyl. Contour, Mystique (VIN 3)
1999 – 2002 2.0L Cougar (VIN 3)
2012 – 2014 2.0L Edge, Explorer (VIN 9)
2001 – 2004 2.0L Escape (VIN B)
2013 – 2014 2.0L Escape (VIN 9), Fusion, MKZ, Taurus
2012 – 2014 2.0L Focus (VIN 2)
2000 – 2004 2.0L Focus (VIN 3)
2002 – 2004 2.0L Focus (VIN 5)
2005 – 2011 2.0L Focus (VIN N)
2014 2.0L MKT
2010 – 2012 2.0L Transit (VIN N)
CAUTION: To prevent damage to the engine, remove the No. 511542 (6475) timing pin from the engine
and reinstall the access plug BEFORE cranking the engine.
1. Rotate crankshaft to set No. 1 cylinder on TDC of compression stroke.
2. Remove the access plug from the engine and install tool No. 511542 (6475) timing pin as shown. (The
pin will completely thread into the hole when the engine is at TDC on the No. 1 cylinder.)
3. Service the timing belt as required according to vehicle service manual procedures.
No. 6475
(511542)
14
WARNING: Wear eye
Form No. 107267
511543 / 511544 (6476) Ford Camshaft Positioning Tool Set
1997 – 2002
1997 – 2002
1998 – 2002
511543
511544
4.6L Econoline, F-Series Truck (VIN W)
5.4L Econoline, Expedition, F-Series Truck
6.8L V10 Econoline
5.4L Navigator
2-Hole
Note:
• 511543 is the same as Ford No. 303-569
(T96T-6256-AR1) and 511544 is the same
as Ford No. 303-570 (T96T-6256-AR2).
• This tool is used with No. 6477 (511545) Ford Camshaft Holding Tool.
1. Two-hole Camshaft Sprocket:
Use No. 511543 to position the camshaft sprocket (2-hole) on
the engine as shown.
18 mm Hex Hd. Camshaft Sprocket:
Use No. 511543 with No. 511544 to position the camshaft
sprocket (18 mm hex hd.) on the engine as shown.
2. Service the timing chain as required according to procedures
in the vehicle service manual.
3. Torque the fasteners to factory specifications.
Camshaft
Sprocket
18 mm
Hex Hd.
Camshaft
Sprocket
No. 511543
No. 511544
No. 511543
WARNING: Wear eye
511545 (6477) Ford Camshaft Holding Tool
1997 – 2002
1997 – 2002
1998 – 2002
No. 6477
(511545)
4.6L Econoline, F-Series Truck (VIN W)
5.4L Econoline (V8), Expedition, F-Series Truck
6.8L V10 Econoline
5.4L V8 Navigator
Note:
• Same as Ford No. 303-557 (T96T-6256-B).
• This tool is used with No. 6476 (511543 & 511544)
Ford Camshaft Positioning Tool Set.
1. Install tool No. 511545 (6477) on the camshaft as
shown.
2. Torque hex hd. bolts at 20 ft.•lbs. to ensure correct
clamping force. Note: Each bolt must be engaged
by the same number of threads in the bottom
clamp to ensure correct clamp alignment.
3. Repair the engine as required according to
instructions in the vehicle service manual.
WARNING: Wear eye
15
511546 (6478) Ford Camshaft Gear Holding Tool
Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E)
1997 – 2008 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X)
2005 – 2010 4.0L SOHC Mustang (VIN N)
No. 511546
(6478)
No. 511550
(6482)
1. Install tool Nos. 511546 (6478) and 511550 (6482)
on the camshaft as shown.
2. Secure tool No. 511546 (6478) to the cylinder head.
3. Service the timing chain as required according to
WARNING: Wear eye
511547 (6479) Ford Crankshaft Holding Tool
Note: Same as Ford No. 303-573 (T97T-6303-A).
1.Install tool No. 511547 (6479) on the
crankshaft damper.
2. Rotate the engine counterclockwise (CCW)
until the tool stops against the engine block.
3. Service the timing chain as required
according to instructions in the vehicle
service manual.
WARNING: Wear eye
16
No. 511547
(6479)
Form No. 107267
511548 (6480) Ford Camshaft Holding Tool Adapter
Note:
No. 511549
• Same as Ford No. 303-576 (T97T-6256-D).
(6481)
• This tool is used with No. 511549 (6481)
Ford Camshaft Holding Tool.
No. 511548
(6480)
1.Install tool Nos. 511548 (6480) and 511549 (6481) on
the camshaft as shown.
2.Secure tool No. 511549 (6481) to the cylinder head.
3.Service the timing chain as required according to
4.Torque fasteners to factory specifications.
WARNING: Wear eye
511549 (6481) Ford Camshaft Holding Tool
Note:
• Same as Ford No. 303-577 (T97T-6256-C).
• This tool is used with No. 511548 (6480) Ford Camshaft Holding Tool Adapter.
No. 511549
(6481)
No. 511548
(6480)
1.Install tool Nos. 511548 (6480) and 511549 (6481) on
the camshaft as shown.
2.Secure tool No. 511549 (6481) to the cylinder head.
3.Service the timing chain as required according to
WARNING: Wear eye
17
511550 (6482) Ford Camshaft Holding Tool Adapter
Application:1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E)
Note:
• Same as Ford No. 303-578 (T97T-6256-A).
• This tool is used with No. 511546 (6478) Ford
Camshaft Gear Holding Tool .
1. Install tool Nos. 511546 (6478) and 511550 (6482)
on the camshaft as shown.
2. Secure tool No. 511546 (6478) to the cylinder head.
No. 511546
(6478)
3. Service the timing chain as required according to
4. Torque fasteners according to factory specifications.
No. 511550
(6482)
WARNING: Wear eye
511551 (6483) Ford Camshaft Synchronizer Tool
Application: 1999 – 2002 4.0L Push Rod Explorer, Mountaineer
1999 – 2000 4.0L Push Rod Ranger
connector. To prevent equipment damage, the connector MUST
be reassembled in the same position during installation.
No. 511551
(6483)
Camshaft
Sensor
Housing
compression stroke.
(6483).
housing.)
according to instructions in the vehicle service manual.
18
WARNING: Wear eye
Form No. 107267
511552 (6484) Ford Timing Chain Tensioner Tool
Note: Same as Ford No. 303-571 (T97T-6K254-A).
1.Remove the hydraulic chain tensioner from the
engine.
2.Install tool No. 511552 (6484) into the engine to
hold pressure on the timing chain during the cam
timing procedure.
3.Adjust camshaft timing according to instructions
in the vehicle service manual.
No. 511552
(6484)
WARNING: Wear eye
511553 / 511554 (6485) Ford Camshaft
Gear Bolt Socket Extension
1997 – 2008
2005 – 2010
2003 – 2011
4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E)
4.0L SOHC Explorer, Mountaineer, Ranger (VIN X)
4.0L SOHC Mustang (VIN N)
4.0L SOHC Ranger
Note: 511553 is the same as Ford No. 303-565 (T97T-6256-G)
and 511554 is the same as Ford No. 303-575 (T97T-6256-F).
No. 6485
(511553 & 511554)
No. 511554
Extension
No. 511553
Camshaft Gear
Bolt Socket
1.Assemble the No. 6485 (511553 & 511554) socket and
extension on the camshaft gear bolt as shown.
Removal: Use a ratchet or breaker bar to loosen and remove
the bolt from the camshaft.
Assembly: Use a torque wrench to tighten the bolt on the
camshaft. Refer to the vehicle service manual for the correct
torque specifications.
WARNING: Wear eye
19
655 Eisenhower Drive
Owatonna, MN 55060 USA
Phone: (507) 455-7000
Tech. Serv.: (800) 533-6127
Fax: (800) 955-8329
Order Entry: (800) 533-6127
Fax: (800) 283-8665
International Sales: (507) 455-7223
Fax: (507) 455-7063
Website: www.otctools.com
Form No. 107267
Issue Date: January 12, 2015 Rev. E
© Bosch Automotive Service Solutions Inc.

No. 6489 Ford Cam and Valve Train Tool Kit

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